Portable manufacturing and assembling facility for modular downhole sand control screens and flow-control devices

ABSTRACT

The present subject matter illustrates a portable-arrangement for assembling a down-hole tool for usage in a well-bore. The arrangement comprises a plurality of intermodal-containers for multi-modal transportation of freight defined by a plurality of modules. The modules are adapted for perforating a received base-pipe, de-burring the perforated pipe, and facilitating assembly of a plurality of screen-units around the base-pipe to achieve a screen assembly for sand and flow control. A roller flow conveyor-module is configured for providing automated-conveyance in respect of the base pipe within and across the modules. Accordingly, the assembling cum manufacturing is achieved at a local location (i.e. onsite) in the country of oil and gas wells operations enabling delivery in shorter lead times, improved inventory management and high in country value.

FIELD OF THE INVENTION

The present disclosure relates manufacturing and assembly of oil-well downhole products used in development and production of oil and gas reservoirs.

BACKGROUND

Manufacturing and assembly of oil-well downhole sand control-screens and flow control devices as used in development and production of oil and gas reservoirs rely on a fixed factory set-up for drilling holes in the basepipe followed by installation of screen filter media over the perforated basepipe, and welding to complete the assembly. Such factory set-up is fixed or permanent and requires significant time and upfront investment to start operations. Moreover, a fixed type factory set-up requires that all raw-material required for manufacturing of sand control screens and flow control devices be first shipped to the country/location of the factory and then the final-assembled product be shipped to oil-well country/location. This involves significant shipping times as base-pipe/raw material location, factory-location and operations location are generally dispersed across different countries in different parts of the world.

Accordingly, there lies at least a need to facilitate a set-up for portable type manufacturing and assembling of oil-well downhole sand control screens and flow control devices locally in the country of operations or at the site of drilling/gas-reservoirs in order to reduce delivery lead times, reduce capital expenditure, improve inventory-management and increase local content in the country of operations.

SUMMARY

This summary is provided to introduce a selection of concepts in a simplified-format that are further described in the detailed description of the invention. This summary is not intended to identify key or essential inventive concepts of the invention, nor is it intended for determining the scope of the invention.

The present subject matter illustrates a portable-arrangement for assembling a down-hole tool for usage in a well-bore. The arrangement comprises a plurality of intermodal-containers for multi-modal transportation of freight defined by a plurality of modules. A first module is adapted for circumferentially perforating a received base-pipe, a second module is provided for de-burring the perforated pipe. A third module is provided for facilitating assembly of a plurality of screen-units around the base-pipe across a pre-defined length of the base-pipe to achieve a screen assembly for at least one of sand and flow control. A roller flow conveyor-module is configured for providing automated-conveyance in respect of the base pipe within each of the first, second and third modules and across the first, second and third modules. Further, the conveyance is rendered for each of the screen-units across the length of the base-pipe.

At least by virtue of aforesaid, the present subject matter renders a portable-manufacturing facility that enables manufacturing and assembly of the downhole sand control-screens and flow control devices, such assembling cum manufacturing taking place at a local location (i.e. onsite) in the country of oil and gas wells operations. In other words, the manufacturing-facility pertains to an assembly of flow-control devices and downhole sand control-screens at a local site to prevent substantial drawbacks otherwise associated with the fixed factory type set-up as used currently for such manufacturing of the oil/gas field downhole products.

To further clarify advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

FIG. 1 illustrates a work-flow for a manufacturing process, in accordance with an embodiment of the present subject matter;

FIG. 2 illustrates workflow of portable plant with equipment-placement, in accordance with an embodiment of the present subject matter;

FIG. 3 illustrates end-view of portable plant-layout, in accordance with an embodiment of the present subject matter;

FIG. 4 illustrates a simulated representation of the portable plant-layout of FIG. 3, in accordance with an embodiment of the present subject matter;

FIG. 5 illustrates a representation of a screen module, in accordance with an embodiment of the present subject matter;

FIG. 6 illustrates method steps in accordance with the workflow of manufacturing-process as depicted in FIG. 1, in accordance with an embodiment of the present subject matter.

Further, skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and may not have been necessarily been drawn to scale. For example, the flow charts illustrate the method in terms of the most prominent steps involved to help to improve understanding of aspects of the present invention. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understand the embodiments of the present invention so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having benefit of the description herein.

DETAILED DESCRIPTION OF FIGURES

For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.

It will be understood by those skilled in the art that the foregoing general description and the following detailed description are explanatory of the invention and are not intended to be restrictive thereof.

Reference throughout this specification to “an aspect”, “another aspect” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrase “in an embodiment”, “in another embodiment” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.

The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such process or method. Similarly, one or more devices or sub-systems or elements or structures or components proceeded by “comprises . . . a” does not, without more constraints, preclude the existence of other devices or other sub-systems or other elements or other structures or other components or additional devices or additional sub-systems or additional elements or additional structures or additional components.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The system, methods, and examples provided herein are illustrative only and not intended to be limiting.

Embodiments of the present invention will be described below in detail with reference to the accompanying drawings.

FIG. 1 illustrates a work-flow for a manufacturing process, in respect of a portable-arrangement for assembling a down-hole tool for usage in a well-bore. More specifically, the present-arrangement facilitates an assembly-process of downhole sand-control screens and flow control devices, in accordance with an embodiment of the present subject matter.

The arrangement comprises a plurality of intermodal-containers for multi-modal transportation of freight. As may be understood intermodal-containers may be used across different modes of transport—from ship to rail to truck—without unloading and reloading their cargo. Such containers may be known as cargo or freight container, ISO container, shipping, sea or ocean container, sea van or (Conex) box, sea can or C can. As a part of the arrangement, the first-container may be defined as a first-module for circumferentially perforating a received base-pipe. The base-pipe comprises a blank-tubular body having a first end, a second end, and a bore there-between forming a flow path for production-fluids. In an example, the first module comprises a drilling-station comprising multiple spindle systems to drill the required perforation pattern on the base-pipe. Further, an optional module may be provided as a part of the first module or the first container for subjecting the base-pipe to a quality-control process prior to undergoing perforation in the first-module.

As shown in the present FIG. 1, as a part of the first module, the process initiates at-least with the reception of a base-pipe and other associated input raw-materials that undergo quality-control/quality-analysis process. Upon having undergone the quality control process, the base-pipe drilling process executes with perforation of the base-pipe at a base-pipe drilling station 102. At this drilling station 102, the drilling machine which is specifically designed to be suitable for this portable type set-up undergoes the drilling program using the multiple spindle-systems that drill the required perforation pattern on the base-pipe.

A second module forming a part of the first container or different container (e.g. a second container) may be provided for de-burring the perforated pipe. The second module subjects the perforated base pipe to undergo cleaning and deburring-mechanism to remove the metallic burrs inside the basepipe. The deburring system is configured to traverse a complete length of perforations and comprises a cleaning-head moving inside the base-pipe, air-circulation to remove debris resulting from the drilling operation, etc.

To put it differently, post base-pipe drilling stage, the perforated-pipe undergoes a cleaning and deburring mechanism 104 as a part of the second module to remove the metallic-burrs from inside the basepipe. Again the deburring-system is designed to ensure it is installed in a portable shipping-container (or an intermodal container) and the cleaning system can work across the complete length of perforations within the basepipe. The cleaning head moves inside the basepipe while air is circulated to remove the metallic-debris left after the perforating process.

A third-module forming a part of other intermodal container (e.g. a third container) is provided for facilitating assembly of a plurality of screen units around the base-pipe across a pre-defined length of the base-pipe to achieve a screen assembly for at least one of sand and/or flow control. The plurality of screen-units are connectable end-to-end to further achieve a pre-defined screen length. Each of the screen unit is adapted to surround the base-pipe for creating an indirect flow path for production fluids moving from a surrounding subsurface formation towards an outer diameter of the base pipes. The plurality of screen-units may be designed as a sand control apparatus, an inflow control device, and an injection control device.

Specifically, the third module is an installation stage pertaining to the installation of prefabricated screen-units. The third module further comprises a resilient-mechanism (e.g. a winch, a pulley mechanism, a spring based winding mechanism, etc.) to guide the plurality of downhole screen units extracted from a screen-stock over a cleaned and drilled base-pipe and thereby enable a concentrical-arrangement of the screen units over the cleaned and drilled base-pipe to provide cover for a pre-defined length of the base-pipe. As a part of guidance over the base-pipe, the screens undergo sliding, pushing, pulling so as to eventually circumscribe the base-pipe at a desired-location.

Further, the third module comprises a first welding-stage for subjecting the plurality of screens units now arranged over the base-pipe (during the installation stage) to undergo welding with each other. A crimping-mechanism is provided for crimping outer edges of the screen units to the basepipe, and a second welding stage for welding the crimped edges to the basepipe, thereby resulting in a finished screen assembly.

In an example, the third module corresponds to a jacket-installation stage 106, wherein a plurality of downhole sand screens (e.g. each module being 4 ft in length) are pulled out from a screen-stock and concentrically arranged over the cleaned and drilled basepipe through a resilient mechanism (such as a winch) so as to provide cover for a specific-length or the entire-length of the basepipe (perforated section). In other example, instead of sand-screens, a plurality of flow-control screens or injection control screens (e.g. each module being 4 ft in length) may be pulled from a screen-stock. Thereafter, at the crimping and welding stage 108 within the third module, the sand-control screens (as concentrically fitted over the base-pipe) undergo welding with each-other followed by crimping of outer edges of the outer screen jackets to the basepipe, and finally followed by welding of these crimped-edges to the basepipe.

The plurality of intermodal-containers optionally comprises a facility (e.g. a fourth module) for subjecting the screen-assembly provided by the third-module to a manual or automated quality-control process to render a quality-checked screen assembly. Finally, the base-pipe as fitted with the sand-control screen undergoes the necessary quality-control process to render a quality-checked sand control screen and/or flow control device. The fourth module may be implemented either through a fourth intermodal container or a makeshift arrangement on-site.

FIG. 2 illustrates the workflow of portable plant with equipment placement, in accordance with an embodiment of the present subject matter.

As shown in the figure, the plurality of rectangles enclosing the modules or stages (i.e. 102, 104, 106 and 108) depicted in FIG. 1 are the portable shipping-containers or intermodal containers that house the base-pipe drilling machine, deburring machine and welding machine. As may be understood, such machines are otherwise fixed structures and heavy structures in a factory, that have been redesigned in accordance with the present subject matter to fit into intermodal containers or shipping-containers. In other words, the shipping-containers exhibit a customised-design that allows sides and/or tops to be removed during the operation for operating upon the drilling machine, deburring, jacket installation and welding-machines. Such shipping-container cum machines being portable in nature may be moved to any facility at any location, plugged to optimum-power and thereby render a fully operational manufacturing plant for oil well sand control screens and flow control devices in no time, thereby doing away with the requirements of investment into a full-fledged factory.

The other miscellaneous requirements of the plant are put together locally (e.g., mechanical handling equipment, power, fluids, waste disposal, etc). In an example, as may be observed from the present FIG. 2 and as further explained in FIG. 4, a roller flow conveyor system is provided to connect one stage to another. The conveyor system represents a deck or a raised platform for automated conveyance. As may be understood, such conveyor system provides an ease of conveyance of the base-pipe from one-stage to another. Further, the aforesaid miscellaneous and high-value investment items are also accommodated within the portable shipping-containers, thereby paving way for a manufacturing unit running in much lower time and with less capital expenditure.

FIG. 3 illustrates an end view of portable plant-layout, in accordance with an embodiment of the present subject matter. As indicated in the figure, the base-pipe undergoes modification at a particular stage and is thereafter rolled from one stage to another via the deck forming a part of the roller flow conveyor system. In other words, each machine stage (i.e. 102, 104, 106, 108) is connected to another through the deck, such that the path between any two stages facilitates an ease of transportation from one stage to another via the deck.

FIG. 4 illustrates a computer-simulated model of the portable plant-layout, in accordance with an embodiment of the present subject matter. As indicated in the FIG. 4 and elaborated in the preceding description, the base-pipe undergoes modification at a particular stage (i.e. 102, 104, 106, 108) and is thereafter conveyed from one stage to another via a roller-flow conveyor module 402.

More specifically, the roller flow-conveyor module 402 is implemented for providing automated-conveyance of the base-pipe for the purposed feeding in and out of each of the first, second and third-modules. For such purpose, the conveyor module 402 comprises a plurality of motion-sources or a first motion providing mechanism for linearly-sliding the base-pipe in and out of any of the module.

Further, the roller flow conveyor module is adapted to move the base pipe from one stage to another. For such purpose, the conveyor module comprises a plurality of motion-sources or a second type of motion providing mechanism for lifting and lowering the base-pipe, and linearly transporting the base-pipe across the stages. In an example, the base-pipe may be pushed from one-module to another module such the base-pipe upon having been pushed rolls to travel from one stage till another stage. The rolling of the base-pipe may be executed over the deck forming a part of the conveyor system. In other example, the roller bearings assist rolling from one stage to another.

The conveyor-module 402 is further adapted for providing conveyance is respect of each of the screen-units across the length of the base-pipe. For such purposes, the conveyor module may drive the winch or any other resilient mechanism to guide (i.e. through pushing, pulling, etc.) the screen modules over the base-pipe. Accordingly, the screen modules are slid over the base pipe and thereby connected end to end.

In an example, the roller flow conveyor module 402 may be transported as a knock-down kit through the intermodal-container as the freight and assembled post-transportation or on site.

FIG. 5 illustrates a representation of a screen-module, in accordance with an embodiment of the present subject matter. The screen-module 500 as depicted in the present figure is a modular sand-screen section. Said screen-section is a result of existing screen technologies utilised in different-way for creation of the screen-modules. In an example, each of the modular screen-module 500 exhibits a 4-ft long size such that each of the modular-screens 500 are assembled as the jacket over the base-pipe (stage 104) and joined end to end through “crimping and welding” (stage 106) so as to render a desired screen-length, e.g. 4 ft to 32 ft long screen. For such purposes, the example 4-ft screen-modules being smaller in nature may also be airfreighted (instead of being sea freight) to reduce shipment-times and costs.

In other implementation, the screen module 500 as depicted may be a sand-screen, an in-flow control device, an injection control device. In an example, the screen may be a wire-wrapped screen, premium screen or any other type of sand control screen for discharging the functions of a sand-control device, a flow-control device, injection-control device, etc.

FIG. 6 illustrates a process for on-site assembly of a down-hole tool for usage in a well-bore.

Step 602 refers setting-up of a roller-flow conveyor-module based on a knock-down kit transportable as freight. As the roller flow conveyor module may be transported as a knock-down kit through the intermodal-container as the freight, the same is assembled post-transportation or on site.

Step 604 refers guiding a base-pipe via the conveyor module to reach a first intermodal-container for circumferentially perforating the base-pipe. In an example, the first container comprises a drilling-station comprising multiple spindle systems to drill the required perforation pattern on the base-pipe. Optionally, the base-pipe may be subjected to a quality-control process prior to undergoing perforation in the first-module.

Step 606 refers further guiding the perforated base-pipe via the conveyor module to reach a second intermodal-container for deburring the perforated pipe. The second container subjects the perforated base pipe to undergo cleaning and deburring-mechanism to remove the metallic burrs inside the basepipe. For example, a cleaning head moves inside the basepipe while air is circulated to remove the metallic-debris left after the perforating process.

Step 608 refers guiding the deburred base-pipe via the conveyor module to reach a third intermodal-container for facilitating assembly of a plurality of screen units around the base-pipe across a pre-defined length of the base-pipe to achieve a screen-assembly, wherein each of the screen unit is adapted to surround the base-pipe for creating an indirect flow path for production fluids moving from a surrounding subsurface formation towards an outer diameter of the base pipe. As a part of guidance over the base-pipe, the screens undergo sliding, pushing, pulling so as to eventually circumscribe the base-pipe at a desired-location. The third intermodal container is adapted to in turn facilitate performance of following steps:

-   (i) guiding a plurality of downhole screen units extracted from a     screen-stock over the deburred base-pipe to achieve a concentrical     arrangement of the screen units over the deburred base-pipe for a     pre-defined length; -   (ii) welding the plurality of screen units arranged over the     base-pipe welding with each other; -   (iii) crimping of outer edges of the screen units to the basepipe,     and -   (iv) welding the crimped edges to the basepipe to thereby result in     the screen-assembly

At least by virtue of aforesaid features, the present subject matter illustrates a workflow of portable plant with equipment-placement, wherein locally available base-pipe and present subject matter's portable manufacturing set-up allows delivery of final product in minimum-possible time at a local location in the country of oil/gas field operations.

More specifically, the portable manufacturing and assembling facility as rendered by the present subject matter at least exhibits a smaller footprint compared to a traditional factory type basepipe and screen assembly plant. As illustrated aforesaid, a substantially shorter turnaround time is required for setting-up the portable assembling unit together with a lower capital expenditure.

Further, the employment of the roller flow conveyor system connecting all the stages end to end does away with the requirement of an overhead crane or any other heavy machinery otherwise required in conventional plants for lifting and lowering the objects such as base-pipe, thereby doing away with a substantial expenditure that is otherwise incurred in conventional plants,

In a nutshell, the present subject matter at least allows local manufacturing and assembly of the sand control screens and flow control devices in locations where it would otherwise be economically unviable to do so or where existing infrastructure is not suitable for large plants. Moreover, the present subject matter leads to a substantial reduction of a total turnaround time by merely requiring base-pipe from local-sources such as an existing inventory and accordingly improves inventory-management for end-users.

While specific language has been used to describe the disclosure, any limitations arising on account of the same are not intended. As would be apparent to a person in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein.

The drawings and the forgoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment.

The scope of embodiments is by no means limited by these specific examples. Numerous variations, whether explicitly given in the specification or not, such as differences in structure, dimension, and use of material, are possible.

Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any component(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature or component. 

We claim:
 1. A portable-arrangement for assembling a down-hole tool for usage in a well-bore, said arrangement comprising: a plurality of intermodal-containers for multi-modal transportation of freight defined by one or more of: a first module for circumferentially perforating a received base-pipe; a second module for de-burring the perforated pipe; and a third module for facilitating assembly of a plurality of screen units around the base-pipe across a pre-defined length of the base-pipe to achieve a screen assembly for at least one of sand and flow control; and a roller flow conveyor module for providing automated conveyance in respect of: (a) the base pipe within each of the first, second and third modules and across the first, second and third modules; and (b) each of the screen-units across the length of the base-pipe
 2. The portable-arrangement as claimed in claim 1, wherein said at-least one base-pipe comprises a blank-tubular body having a first end, a second end, and a bore there-between forming a flow path for production fluids.
 3. The portable-arrangement as claimed in claim 1, wherein said plurality of screen units are connectable end to end to further achieve a pre-defined screen length on-site, each of the unit adapted to surround the base-pipe for creating an indirect flow path for production fluids moving from a surrounding subsurface formation towards an outer diameter of the base pipes.
 4. The portable-arrangement as claimed in claim 1, wherein said plurality of screen-units are pre-configured as at least one of: a sand control apparatus; an inflow control device; and an injection control device
 5. The arrangement as claimed in claim 1, wherein at least one of the plurality of intermodal containers comprises a fourth module for subjecting the base-pipe to a quality-control process prior to undergoing perforation in the first module.
 6. The arrangement as claimed in claim 1, the first module comprises a drilling station comprising multiple spindle systems to drill the required perforation pattern on the basepipe.
 7. The arrangement as claimed in claim 1, wherein the second module subjects the perforated base pipe to undergo cleaning and deburring mechanism to remove the metallic burrs inside the basepipe.
 8. The arrangement as claimed in claim 1, wherein the deburring system is configured to traverse a complete length of perforations and comprises: a cleaning head moving inside the basepipe; air-circulation to remove debris resulting from the drilling operation.
 9. The arrangement as claimed in claim 1, wherein the third module is an installation stage pertaining to the installation of a prefabricated screen-unit and comprises a resilient-mechanism to: guide the plurality of downhole screens units extracted from a screen-stock over a cleaned and drilled base-pipe and thereby enable a concentrical arrangement of the screen units over the cleaned and drilled base-pipe to provide cover for a pre-defined length of the basepipe.
 10. The arrangement as claimed in claim 9, wherein the third module further comprises: a first welding stage for subjecting the plurality of screens units arranged over the base-pipe during the installation stage to undergo welding with each other a crimping stage for crimping outer edges of the screen units to the basepipe, and a second welding stage for welding the crimped edges to the basepipe, thereby resulting in a finished screen assembly.
 11. The arrangement as claimed in claim 1, wherein the plurality of intermodal containers optionally comprise a facility for subjecting the screen-assembly provided by the third module to a manual or automated quality-control process to render a quality-checked screen assembly.
 12. The arrangement as claimed in claim 1, wherein the roller flow conveyor module is transported as a knock-down kit through the intermodal container as the freight and assembled post-transportation.
 13. The arrangement as claimed in claim 1, wherein the roller flow conveyor module in the assembled state comprises: a deck defined by a raised platform; and a plurality of motion sources defined by one or more of: a first type of mechanism for linearly sliding the base-pipe in and out of any of the module; a second type of mechanism for lifting and lowering the base-pipe; and a third type of mechanism for pushing the base pipe to roll from one module to another module.
 14. A process for on-site assembly of a down-hole tool for usage in a well-bore, said process comprising: setting up a roller flow conveyor module based on a knock-down kit transportable as freight; guiding a base pipe via the conveyor module to reach a first intermodal-container for circumferentially perforating the base-pipe; said base-pipe comprising a blank-tubular body having a first end, a second end, and a bore there-between forming a flow path for production fluids; further guiding the perforated base-pipe via the conveyor module to reach a second intermodal-container for deburring the perforated pipe; and further guiding the deburred base-pipe via the conveyor module to reach a third intermodal-container for facilitating assembly of a plurality of screen units around the base-pipe across a pre-defined length of the base-pipe to achieve a screen-assembly, wherein each of the screen unit is adapted to surround the base-pipe for creating an indirect flow path for production fluids moving from a surrounding subsurface formation towards an outer diameter of the base pipe.
 15. The process as claimed in claim 14, wherein the third intermodal container is adapted to enable performance of at least one of: guiding a plurality of downhole screens units extracted from a screen-stock over the deburred base-pipe to achieve a concentrical arrangement of the screen units over the deburred base-pipe for a pre-defined length; welding the plurality of screens units arranged over the base-pipe welding with each other; crimping of outer edges of the screen units to the basepipe, and welding the crimped edges to the basepipe to thereby result in the screen-assembly. 